GT-3500GE NEW MODELOPERATOR,S INSTRUCTION MANUAL

PORTABLE IMPACT WRENCH

・ SPEC TYPE (Documents Included)・USA GAS EMISSION CONTROL VERSION(EPA PHASE/CARB Tier 1)・INTERNATIONAL SPEC MODEL

2001 Edition

T o o l s s i n c e 1 9 1 6

R

99093030.02 Printed in Japan.

Product of Japan

No. 17-25, Fukae Kita 2-chome, Higashinariku, Osaka 537-0001 Japan

Tel :+81 6 976 7778 　　Fax :+81 6 972 9441

Manufactured by:

®

　 SPEC TYPE

Email:export@vessel.co.jp　　　URL http://www.vessel.co.jp/exp/

Copyright VESSEL CO., INC. 2001C

TECHNICAL DATA -----------------------------------------------------

WARNINGS & SAFETY INSTRUCTIONS ------------------------

OPERATING INSTRUCTION ----------------------------------------

TROUBLE SHOOTING ------------------------------------------------

MAINTENANCE INSTRUCTION ------------------------------------

EXPLODED VIEWS AND SPAREPARTS LISTS ---------------

Engine - Exploded Diagram Drawing -------------------------------

Engine - Parts List ------------------------------------------------------

Engine components - Exploded Diagram Drawing -------------

Engine components - Parts List -------------------------------------

Recoil Starter - Exploded Diagram Drawing & Parts List ------

Carburetor - Exploded Diagram Drawing & Parts List ---------

Impact Mechanism - Exploded Diagram Drawing ---------------

Impact Mechanism - Parts List ---------------------------------------

1

2～3

4～5

6～8

9～11

12

13

14

15

16

17

18

19

20

PAGE No.

GASOLINE ENGINE IMPACT WRENCH

OPERATORS MANUAL & SPAREPARTS LISTS

"PHANTOM" moves quickly!

PORTABLE

PORTABLE

INDEX

CHAPTER 1.

CHAPTER 2.

CHAPTER 3.

CHAPTER 4.

CHAPTER 5.

CHAPTER 6.

TECHNICAL DATA

Note: To improve the performance, the specifications are subject to change without notice.

CHAPTER 1.

INTRODUCTION

Engine TypeDisplacementFuel Tank CapacityFuel Mixture RatioRevolution(idling)Revolution(loaded, impact)Revolution(non loaded, max)Maximum OutputMaximum TorqueCompression RateFuel Consumption Rate

:Two Stroke, Forced, Air Cooled, Single Cylinder: 46.5cc, Φ43x32mm(Inner bore size x stroke): 1 liter: 25:1(gasoline : 2 cycle oil): 2700 rpm ±250: 7120 rpm: 9880 rpm: 2.3 Ps/7500 rpm: 0.34 kg-m/5500 rpm: 7.1 : 1: 380 g/Ps.h

Ignition TypeSpark Plug Type

: Electronic: NGK BPMR6A

Vibration UnloadedLoaded

: 4m/S2

: 19m/S2

Noise IdleLoaded

: 78dBA: 100dBA

Carburetor Type : Diaphragm

Impact Square Drive SizeFastening Torque Range

Free Speed

: 25.4 mm(1"): 1030Nm(Full Throttle : 760ft. lbf) 800Nm(Half Throttle : 590ft. lbf): 1200 rpm

Capacity Bolt Diameter : 32 mm (1 1/4")

Weight Without fuel : 19.50 kg (42.99 lbs.)

Overall Dimensions LengthHeightWidth

: 700mm (28"): 330mm (13"): 390mm (15")

Accessories Hex Key Wrench

Spark Plug WrenchSpanner

4mm 1pc. 5mm 1pc. 6mm 1pc. 1pc.10-13mm 1pc.

GT-3500GE GASOLINE ENGINE IMPACT WRENCH is a high quality tool with self-contained heavy duty and high power two cycle engine as power source. And its unique design of impact mechanism with VESSEL pneumatic V-Hammer ultra light weight impact wrench series, even small engine (46.5 cc) can create higher fastening torque with enormous light weight only 19.50kg (42.99 lbs.)

Because of self-contained high power two cycle engine, it is very easily mobile to carry by one man to any construction sites in the rain forest, hill or desert such remote areas where electricity supply or air compressor, generator are not available.

The capacity of this tool is 32mm (1 1/4") bolt size and ideal for fastening and loosening bolts of wood sleepers at railroad construction and many more applications.

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WARNINGS AND SAFETY INSTRUCTIONSCHAPTER 2.

Read these instructions carefully before operating, maintaining or servicing this tool. Please keep these instructions in a safe accessible place.

Read to fully understand and observe the following safety precautions and warnings. Careless or improper use of tool may cause serious or fatal injury.

WARNING!Indicates instant possibility ofsevere personal injury or loss of life, if instructions are not followed.

Always wear eye, head and ear protectors when using this tool.

CAUTION!Indicates a possibility of per-sonal injury or equipment dam-�age, if instructions are notfollowed.

Always wear a safety face shield or goggles.Always wear heavy, long pants, boots and gloves. Do not wear loose clothing, jewellery, short pants, sandals or go barefoot. Secure hair so it is above shoulder length.Do not operate that tool when you are tired, ill or under the influence of alcohol, drugs or medication.Never let a child or inexperienced person operate the machine.Wear hearing protection.Never start or run the engine inside a closed room or building. Breathing exhaust fumes can kill.Keep handles free of oil and fuel.Keep hands away from anvil.Do not grab or hold the unit by rotating anvil.Hold the handles firmly with both hands and make sure to stand on the firm base or ground.Do not touch spark plug, high voltage cord du-ring operation as it may cause electric shock.To avoid burn do not touch those places like engine, muffler, exhaust where get very hot during in use or even after stop engine until it gets cool for the time being.When operation is prolonged, take a break from time to time so that you may avoid pos-sible whitefinger disease which is caused by vibration.

Operator safety

Inspect the entire tool before each use. Re-place damaged parts. Check for fuel leaks and make sure all fasteners are in place and se-�curely fastened.Replace parts that are cracked, chipped or damaged in any way before using the tool.Keep others away when making carburetor adjustments.Use only accessories as recommended for this tools by the manufacturer.

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Tool safety

Never modify the tool in any way. Do not use your tool for any job except that for which it is intended.

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Fuel safety

Mix and pour fuel outdoors and where there are no sparks or flames.Use a container approved for fuel.Do not smoke or allow smoking near fuel or the tool or while using the tool.When filling up fuel, stop engine and make sure engine is cool and choose the places where no flamables and well ventulation.Wipe up all fuel spills before starting engine.

WARNING!

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Maintain the tool according to recommended procedures. Disconnect the spark plug before performing maintenance except for carburetor adjust-ments.Keep others away when making carburetor adjustments.Use only genuine replacement parts as rec-ommended by the manufacturer.

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Maintenance safety

Carry the tool by hand with the engine stopp-�ed and the muffler away from your body.Allow the engine to cool, empty the fuel tank, and secure the tool before storing or trans-porting in a vehicle.Empty the fuel tank before storing the tool. It is recommended that the fuel be emptied after each use. If fuel is left in the tank, store so fuel will not leak.Store tool out of the reach of children.Clean the unit carefully and store it in a dry place.Make sure engine switch is off when trans-porting or storing.

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Transport and storage

If situations occur which are not covered in this manual, take care and have a good judgement. Contact your dealer if you need assistance.

Move at least 3m away from fueling site before starting engine.Stop engine before removing fuel cap.Empty the fuel tank before storing the tool. It is recommended that the fuel be emptied after each use. If fuel is left in the tank, store so fuel will not leak.Store tool and fuel in area where fuel vapors cannot reach sparks or open flames from water heaters, electric motors or switches, furnances, etc.

Antivibration systems do not guarantee that you will not sustain whitefinger disease or car-pal tunnel syndrome. Therefore, continual and regular users should monitor closely the condition of their hands and fingers. If any of the above symptoms appear, seek medical advice immediately.

WARNING!

(7)

(8)

(9)

(10)

OPERATING INSTRUCTION CHAPTER 3.

Use only quality two cycle oil with gasoline at mixture ratio of 25:1 (Gasoline : Two cycle oil) (FIG. 3)

1.FUEL

*Never use by gasoline only as engine will burn.

(1)(2)(3)

(4) (5)

(6)

Place the tool on a firm stand or solid floor.Set gear change lever to neutral (N) position. (FIG. 3-2)Press priming bulb several times so that fuel flows through bulb into carburetor. (FIG.3-3)Turn choke lever to closed position. (FIG. 3-4)Pull throttle lever,and then press the support button.then the throttle lever is stayed there in the state of half-throttle,and won't be back to the original location. (FIG.3-5)Pull recoil starter handle strongly, taking care to keep the handle in your grasp and not allow to withdraw rope until the end. (FIG.3-6)

After initial fires, engine will continue to run, return choke lever slowly to open position.If engine will stop after a few fires by procedure of (7), return choke lever to open position and pull recoil starter handle strongly again.If engine does not start by procedure of (8), repeat procedures from (4).After starting engine, return throt t le lever to idle position for slow engine. Then allow the engine about 2～3 minutes to warm up before in use.

2.START UP ENGINE

WARNING!

CAUTION!

Do not smoke and keep all other fire away from fuel tank during filling fuel as it causes fire or burn yourself. (FIG .3-1)

*Once starting the engine, do not leave tool alone. Always hold han- dle tightly so that tool will not move around on the stand or floor.*Before and during operation, always take a firm stance and keep safety position from slipping of falling down.

Wipe up all fuel spills before starting engine.

CAUTION!

Return recoil starter rope gently to its original position.

Fill up fuel after well mixed fuel and oil in a separate clean container.

WARNING!

251

GASOLINE TWO CYCLE OIL

GEAR CHANGE LEVER

(FIG.3)

(FIG.3-1)

OIL POT PORT(FIG.3-2)

PRIMING BULB

CLOSED

OPEN

CHOKE LEVER

(FIG.3-3)

(FIG.3-6)

(FIG.3-4)

PRESS

(FIG.3-5)

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OPEPATING INSTRUCTION CHAPTER 3.

(1)

(2)

(3)

(4)

Select R (for clockwise direction) or L (counter clockwise di-rection) gear for fastening or loosening bolts and nuts.Always release thrott le lever to allow slow engine for idling and turn gear change lever and do not change gear when engine is accelerating.This new model has implemented an adjustment button in order to operate two different torque values.A.FULL THROTTLE(MAXIMUM TORQUE)1030 Nm If you squeeze the throttle lever fully, the machine shows the maximum torque,1030Nm.B.HALF THROTTLE(MEDIUM TORQUE) about 800Nm 1.Press the adjustment button. 2.Squeeze the throttle lever and the adjustment valve will prevent the throttle lever from moving further more. In other words, the throttle lever would hit at the adjustment valve and would not create further torque. (FIG.3-8)

Fine tune might be required by turning adjustment button from number 1 to 3. The number should be set at the yellow sign area.(FIG.3-9)

Once bolts or nuts fastened, release throttle lever for idling and not allow driving shaft turn and remove socket from bolts or nuts.

3.OPERATION.

(1)(2)(3)

Release throttle lever to decrease engine speed.Push stop switch to stop engine. (FIG. 3-10)Place the tool on firm stand or solid floor and turn gear change lever to N (neutral) position.

4.STOPPING ENGINE

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CROSS SECTION SKETCH Adjustment button

Throttle lever

move

move

PRESS

Throttle lever

ADJUSTMENT BUTTON

2

3 2

1

Yellow Sign

STOP SWITCH

(FIG.3-8)

(FIG.3-9)

(FIG.3-10)

TROUBLE SHOOTING - 2CHAPTER 4.

ENGINE INSTALLEDSOON AFTER STARTING OR IS LIKELY TO STOP

Fill up fuel at mixture ratio of 25 gasoline : 1 two cycle oilTurn to open positionCheck if cracks are found on pipe or connector and pipe is securely fixedAir leak from carburetor Incorrect carburetor adjustment Bad diaphragm in carburetorIncorrect carburetor valve hinge height adjustment

<Fuel System>●

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●

Shortage of fuelChoke lever in closed positionAir goes through to fuel system

Poor function of carburetor

<Electrical system>●

●

Bad spark plugBad ignition coil

CORRECTIVE ACTIONPROBABLE CAUSESYMPTOM

ReplaceReplace

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_7

CHAPTER 4.

ENGINE OVERHEATS

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TROUBLE SHOOTING - 3

Bad mixture ratio fuelWrong selection of spark plugClogged cylinder with dirtClogged cooling duct with dirt

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Gear change lever in neutral position

Worn out of drum shoe on clutch arm

Fill up correct mixture ratio fuel at 25 gasoline : 1 two cycle oilReplace. Use pure and instructed parts onlyClean upClean up

Turn to R (clockwise direction) or L (counter clockwise direction) positionReplace

NON-REVOLUTION OF ANVIL SHAFT

CORRECTIVE ACTIONPROBABLE CAUSESYMPTOM

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Dirty air cleaner elementCarbon deposits in muffler, exhaust port on cylinderPoor cylinder pressure due to worn out of piston, piston ring, cylinderWorn out of anvilWorn out of clutchWorn out of cam plateWorn out of hammerBroken of return spring

Clean upClean up

Replace

ReplaceReplaceReplaceReplaceReplace

OUTPUT POWER REDUCTION

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MAINTENANCE INSTRUCTIONCHAPTER 5.

It is recommended to practice regular check-up and maintenance in accordance with usage frequency to keep your tool better condition and long life and eventually it reduces total run-ning costs.This practice also protects you from serious injuries.

* Rinse the fuel tank with gasoline.* Clean the exterior of the carburetor and the space around it.* Clean the fan and the space around it.

(1)

(2)

(3)

When the engine is test run at the factory, the carburetor is properly adjusted, do not try to touch it.When idle speed is higher (when the anvil is rotating) or lower (engine will stop), adjust to correct speed by idle adjustment screw.

How to adjust L adjustment screw(lower speed fuel adjust-�ment) and H adjustment(higher speed fuel adjustment)

1. CARBURETOR ADJUSTMENT

MAINTENANCE/CHECK-UP/REPAIRING

Daily Check-Up* Check all nuts and screws are securely tightened.* Check fuel level, and when filling up fresh fuel, wipe up spill and clean fuel tank.* Check oil level of gear box through window. Oil level should be center of window and if lower than this level, add oil to this level.

Weekly Maintenance* Check the starter, especially cord and return spring.* Clean the exterior of the spark plug.* Remove spark plug and check the electrode gap. Adjust it to 0.6 mm, or change the spark plug.* Clean the cooling fins on the cylinder and check that the air intake at the starter is not clogged.* Clean the air filter.

Monthly Maintenance

Turn to clockwise for higher idleTurn to anti clockwise for lower idle (FIG. 5-1)

①

②

③

Under idle condition, turn L adjustment screw to right orleft to look for the peak of idle speed. And from this position,return adjustment screw to the left 1/8-1/4 turn.Full open throttle lever and turn H adjustment screw to right or left and follow the same procedures as L adjust-�ment screw explained.Standard return screw degrees are :

L adjustment screw : 1 1/8 return from full closed H adjustment screw : 1 1/8 return from full closed

(1) Remove spark plug and touch it to metal part except spark plug mounting thread.

(2) Pull recoil starter handle.

2. CHECK-UP SPARK CONDITION

* Never touch spark plug to the area at spark plug mounting thread since remaining gas might be exploded.

* When pulling recoil starter handle, do not touch the metal part of spark plug or you will get electric shock.* After wipe and clean up fuel around the place where spark plug to touch and make sure no fire possibility and check spark plug.

(3) When in normal condition, you see spark.

(1) Use recommended type of spark plug.(2) In a best operation condition, electrodes on the spark plug show dark brown and keep dry.

If the spark plug is dirty, clean it and check the electrode gap. If readjustment is necessary, the correct gap is 0.6mm.

The spark plug condition is influenced by the following factors ;

* An incorrect carburetor setting.* Wrong fuel mixture (too much oil in the gasoline).* A dirty air filter.* Hard running conditions (under cold weather operation).

The spark plug should be replaced after about 100 operation hours or earlier if the electro-des are badly eroded.

3. SPARK PLUG (FIG. 5-2)

(1) When the air filter gets dirty and closed with dust, it will cause various troubles :

* Carburetor malfunctions.* Starting problems.* Engine power reduction.* Unnecessary wear on the engine parts.* Abnormal fuel consumption.

(2) Cleaning the air filter

Air filter must be cleaned from dust and dirt regularly and damaged filter must be replaced with a new one.

* Remove the air filter cover and the filter.* Rinse it in warm soap suds and wring tight and dry it before re-assembly.* Damaged air filter must be replaced with a new one.

4. AIR FILTER (FIG. 5-3)

WARNING!

WARNING!

IDLE ADJUSTMENT SCREW

(FIG.5-1)

(FIG.5-2)

REMOVE CARBON

(FIG.5-3)

AIR FILTER(CLEANER SPONGE)

0.6mm

_ 　 _11 _ 　 _12

(1)

5. FUEL FILTER (FIG. 5-4)If fuel filter is clogged with impurities in the fuel, fuel will not flow into carburetor and it will make engine malfunction. Regular check-up is recom-mended.

* Drain all fuel from fuel tank and pull out fuel filter line from tank.* Pull filter element out of holder assembly and rinse element in warm water with detergent.* Rinse thoroughly until all traces of detergent are eliminated.* Squeeze, but do not wring and keep dry.* If element is too dirty, replace it.

(1) Engine power reduction maybe cause by a lot of carbon accumulated around exhaust port on cylinder, muffler inlet or outlet in the long use. Regular clean-up is recommended.

* Remove the muffler and clean up any excess carbon from the exhaust port or muffler inlet every 100 hours of operation.* When cleaning up, remove carbon carefully not to hurt piston, cylinder and do not let carbon into crank case.

6. MUFFLER (FIG. 5-5)

(1) When contact places of anvil and hammer become worn-out to be dull by percussion, the tool becomes output power reduction and due to extra longer percussion than normal condition it will cause damage and earlier broken of parts.* Empty all oil in the gear box and remove hammer housing complete and check the degree of worn-out of anvil and hammer at least once every month. And give grease around hitting area.

7. IMPACT MECHANISM

(1)(2)

(3)

(4)(5)(6)(7)(8)

Clean each part and apply two cycle oil on the metal part to prevent from corrosion.To keep tool for a long time(more than 3 weeks), drain fuel from fuel tank and keep running engine without load until the engine will stop and exhaust all remaining fuel in the carburetor.Remove spark plug and pure two cycle oil into cylinder and pull recoil starter handle several times to spread oil.Stop the recoil starter handle when you feel engagement.Damaged parts should be repaired before storage.Keep the tool where the place without dust, humidity also the temperature below 50 ℃.Store tool out of the reach of children.Keep fuel into safety container in the cool room or place where no flammable. And do not use stale fuel as it causes engine troubles.

8. STORAGE

1.

2.

3.

4.

5.

6.

When order for spareparts, please indicate index number, part name and quantity.

Quantity as number required here is for one unit.

V marks indicate over-size shims for precise adjustment.

Minimum order is 10 pcs. or more for such small items like screws, nuts and washers.

Each spareparts for engine is not supplied but as assembly or com-plete set only except spark plug.

Specifications are subject to change without notice.

EXPLODED VIEWS AND SPAREPARTS LISTSCHAPTER 6.

SPAREPARTS ORDER

= NOTE =

(FIG.5-4)

(FIG.5-5)